Piezo Direct Unveils Advanced Mesh-Based Atomizer for Inhalation Devices

Piezo Direct, a company specializing in piezoelectric components and assemblies, has unveiled a groundbreaking mesh-based piezo atomizer designed for nebulizing and vaping applications. This innovative product stands out due to its advanced safety features and precise control over droplet size, making it a significant advancement in the field of inhalation devices.

The new atomizer eliminates the common issue of laser-drilled holes leaving behind metal debris, a problem that can contaminate the mist and potentially harm users. By developing a proprietary process that removes the metal residue without affecting the hole geometry, Piezo Direct ensures a cleaner and safer inhalation experience. The company claims that this process makes their atomizers the best in class for applications where the user inhales the mist.

According to Li Hsu, CEO of Piezo Direct, "Safety is our number one priority when it comes to designing mesh-based piezo atomizers for human inhalation applications. We have made a significant investment in both the design and the manufacturing of these atomizers to ensure they are the safest available." The process removes the "volcano" of resolidified metal that typically forms around the rim of the holes during laser drilling, a feature that can release particles into the mist and potentially harm the user.

The atomizer features micro-holes as small as 2.0 microns, which is crucial for producing droplets that can reach the lower respiratory tract. The median droplet size measures roughly 1.5 to 2.0 times the hole's exit diameter, with droplets between 1 and 5 microns being the most effective for inhalation. Piezo Direct has managed to hold the hole size at 2.0 to 2.5 microns with a precision of ±0.3 microns, delivering a Mass Median Aerodynamic Diameter of 3.0 to 4.2 microns.

The atomizer is made from titanium, a material that resists aggressive drug formulations, hypertonic saline, and hydrogen peroxide vapor sterilization. It can withstand continuous flexure above 100 kHz, making it suitable for high-frequency applications. The company has developed a post-process that removes the recast lip and surrounding spatter without affecting the hole geometry or damaging the base material. This ensures that no molten residual particles are visible under scanning electron microscopy, making the atomizer more reliable and safer for use.

Piezo Direct's atomizers are now available for a range of applications, including nebulizers, inhalers, vaping devices, and portable personal care atomizers. The company also supports industrial applications such as semiconductor humidification, precision coating, and aroma diffusion. Device engineering teams can request samples or discuss custom mesh specifications on the company's website, piezodirect.com, where a technical white paper detailing the process is also available.

Piezo Direct is currently working on developing sub-1.5-micron holes, thin-film titanium alloys, and 100 percent inline optical inspection of every hole on every plate. These advancements aim to further enhance the safety and precision of their atomizers, ensuring that they continue to set the standard in the industry.